Double-structure headwear and manufacturing method thereof

ABSTRACT

A double-structure headwear and a manufacturing method thereof may provide improved productivity by easily forming the double-structure headwear and provide a shielding effect against external heat and wearing comfort. The double-structure headwear includes a first wearing portion, and a second wearing portion being disposed on an inner side of the first wearing portion. The first and second wearing portions have each lower portion sewed and folded to a predetermined height in a vertical direction, and the first wearing portion has a lower thermal conductivity and lower contact thermal sensation than that of the second wearing portion.

BACKGROUND OF THE INVENTION

(a) Field of the Invention

The present invention relates to a double-structure headwear and a manufacturing method thereof. More particularly, the present invention relates to a double-structure headwear and a manufacturing method thereof capable of providing improved productivity by simplifying a manufacturing process of the double-structure headwear, wearing comfort, and shielding effect against an external heat.

(b) Description of the Related Art

Generally, a headwear includes a crown portion formed in a hemispherical shape so as to cover a head and a visor portion connected at a front of the crown portion so as to shield sunlight or the like. Particularly, the expression “double-structure headwear” means that the crown portion has an inner fabric and an outer fabric. The double-structure headwear may provide two or more shapes, and may also increase warmth retention.

However, in order to manufacture such a double-structure headwear, the inner and outer fabrics are pre-sewed to each other, and then a sewing portion thereof is wrapped with a tape or the like such that the sewing portion is prevented from being exposed. Accordingly, there is a problem in that the inner and outer fabrics must be sewed many times, and accordingly, a headwear may not provide a slim-design and may have decreased elasticity.

In order to prevent the sewing portion from being exposed, the inner and outer fabrics have an opening portion at a part of the sewing portion thereof, and the inner and outer fabrics are turned upside down through the opening portion, thereby form a double-structure headwear.

However, there are problems in that the headwear may be abnormally formed because the inner and outer fabrics are turned upside down through the opening portion, and it is difficult to turn upside down the inner and outer fabrics of the crown portion through the narrow opening portion.

Further, the headwear may have a knotted surface because the portions for wrapping the sewing portions may be exposed, and thus, a user may feel uncomfortable when putting on and taking off the headwear.

In addition, when a thick fabric may be used to manufacture a baseball cap, the thick fabric may form a thick seam or wrapped member, which may be in danger of being broken by a hair pin or hair. In addition, the user may feel unpleasantly hot when the user may put on the headwear formed by such a thick fabric having a low contact thermal sensation.

Also, younger people prefer a slim design and dislike the headwear using a size adjusting device due to a sense of oppression felt thereof.

The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.

SUMMARY OF THE INVENTION

The present invention has been made in an effort to provide a double-structure headwear and a manufacturing method thereof having advantages of providing good productivity by simplifying a manufacturing process of the double-structure headwear.

In addition, the present invention has been made in an effort to provide a double-structure headwear and a manufacturing method thereof having advantages of providing an excellent shielding effect against an external heat by forming a crown portion to have an inner fabric and an outer fabric.

In addition, the present invention has been made in an effort to provide a double-structure headwear and a manufacturing method thereof having advantages of providing functions of sweat-absorbing and cushioning without an additional sweat absorber, thereby reducing a total number of constituent elements and simplifying a manufacturing process.

In addition, the present invention has been made in an effort to provide a double-structure headwear and a manufacturing method thereof having advantages of providing little uncomfortable sense and sense of oppression felt and providing a slim and excellent design by using minimum sewing lines.

A double-structure headwear according to an exemplary embodiment of the present invention in one aspect of the present invention includes a first wearing portion; and a second wearing portion being disposed on an inner side of the first wearing portion, wherein the first and second wearing portions have each lower portion folded to a predetermined height in a vertical direction and sewed to each other, and the first wearing portion has a lower thermal conductivity and lower contact thermal sensation than that of the second wearing portion. The double-structure headwear may further include first and second core members respectively disposed on each folded lower portion. The double-structure headwear may further include a size tape having a constant length and entirely disposed on each lower portion of the first and second wearing portions. The second wearing portion may be formed by polyester or a mixed spinning of cotton and polyester in a ratio of 6 to 4. The first and second core members may be formed by a non-woven fabric and the first core member may be thicker than the second core member. For example, the first and second core members may be formed of about 100% polyester, the first core member may have a thickness of about 1.0 mm and a weight of about 101.56 g/m², and the second core member may have a thickness of about 0.8 mm and a weight of about 78.12 g/m². The size tape may have high elasticity in a vertical direction; the first and second core members may have sweat absorptive and cushioning properties. The first wearing portion has a seam portion for connecting a plurality of fabric pieces and being pre-sewed with each other and sewed in one-to-one with a tape of a predetermined width, and the second wearing portion has a seam portion for connecting a plurality of fabric pieces and being pre-sewed with each other.

A manufacturing method for a double-structure headwear according to an exemplary embodiment of the present invention in another aspect of the present invention includes forming a first wearing portion including pre-sewing a plurality of fabric pieces to form a seam portion, dividing the seam portion in one-to-one, and again sewing the divided sewing portion in one-to-one with a tape; forming a second wearing portion including pre-sewing a plurality of fabric pieces having a higher thermal conductivity and higher contact thermal sensation than those of the first wearing portion; folding each lower portion of the first and second wearing portions to a predetermined height to form each folded portion; sewing in one-to-one each folded portion of the first and second wearing portions.

Forming the folded portions may further include respectively disposing a first core member and a second core member thinner than the first core member on each lower portion of the first and second wearing portions, disposing a size tape on each lower portion of the first and second core members, and folding each lower portion of the first and second wearing portions along with each lower portion of the first and second core members by a width of the size tapes. The one-to-one sewing of the folded portions may include disposing one end of a visor portion between each folded portion of the first and second wearing portions and entirely sewing the one end of the visor portion with the folded portions of the first and second wearing portions. Forming the folded portions may further include respectively stitching the first wearing portion, the first core member, and the tip portion of the size tape along with the second wearing portion, the second core member, and the tip portion of the size tape. The first and second core members may be non-woven fabric.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a headwear according to an exemplary embodiment of the present invention.

FIG. 2 is a bottom view of FIG. 1.

FIG. 3 is a cross-sectional view taken along line A-A of FIG. 2.

FIG. 4 is a cross-sectional view taken along line B-B of FIG. 2.

FIG. 5 illustrates a graph showing power consumption for maintaining a head temperature in which mannequin respectively puts on a double-structure headwear according to an exemplary embodiment of the present invention and a conventional headwear.

DETAILED DESCRIPTION OF THE EMBODIMENT

An exemplary embodiment of the present invention will hereinafter be described in detail with reference to the accompanying drawings.

As those skilled in the art would realize, the described embodiment may be modified in various different ways, all without departing from the spirit or scope of the present invention.

A double-structure headwear and a manufacturing method thereof according to an exemplary embodiment of the present invention are described in detail with reference to the accompanying figures.

FIG. 1 is a perspective view of a headwear according to an exemplary embodiment of the present invention, and FIG. 2 is a bottom view of FIG. 1. FIG. 3 is a cross-sectional view taken along line A-A of FIG. 2, and FIG. 4 is a cross-sectional view taken along line B-B of FIG. 2.

According to an exemplary embodiment of the present invention, a headwear 100 includes a wearing portion 10 for covering a head of the wearer and a visor portion 30 for shielding sunlight. The visor portion 30 may be connected at a front of the wearing portion 10.

The wearing portion 10 may be formed in a double-structure having a first wearing portion 11 and a second wearing portion 21. The first wearing portion 11 may be formed in a hemisphere and have a plurality of fabric pieces connected to each other. The second wearing portion 21 may also be formed in a hemisphere corresponding to the shape of the first wearing portion 11, but may be formed by different material from the material of the first wearing portion 11. For example, the material of the second wearing portion 21 may have a higher thermal conductivity and a higher contact thermal sensation than those of the first wearing portion 11.

The first wearing portion 11 may be provided with a front core member 12 for reinforcing the first wearing portion 11 at a front thereof. The front core member 12 is connected along with the first wearing portion 11 to the visor portion 30.

A first core member 13 may be provided instead of the front core member 12 at a side of the first wearing portion 11. The first core member 13 may be integrally formed with the front core member 12.

The second wearing portion 21 may also be provided with a second core member 22 disposed in a circumferential direction at a lower portion thereof.

The first and second core members 13 and 22 are provided on each lower portion of the first and second wearing portions 11 and 21 and folded at each lower portion thereof to a predetermined height (herein, the predetermined height is defined as a width of each lower portion thereof folded in a head height direction), thereby forming each folded portion 16 and 26. Each folded portion 16 and 26 thereof is entirely sewed with each other, so that the first and second wearing portions 11 and 21 are connected at each lower portion.

The first and second core members 13 and 22 may be very elastically folded in a vertical direction (herein, the vertical direction means a head-height direction) so that each lower portion of the first and second core members 13 and 22 may be easily folded at the predetermined height along with each lower portion of the first and second wearing portions 11 and 21.

According to an exemplary embodiment of the present invention, the first and second core members 13 and 22 may be formed by a non-woven fabric of about 100% polyester. Also, the first core member 13 may have a thickness of about 1.0 mm and a weight of about 101.56 g/m², but the second core member 22 has a thickness of about 0.8 mm and a weight of about 78.12 g/m². That is, the second core member 22 may be formed thinner and lighter than the first core member 13. Accordingly, when the first and second core members 13 and 22 are pressed to each other, the wearing portion 10 may have an enough thickness to provide good sweat absorptive and cushioning properties for the wearer's forehead. In addition, although the first core member 13 may have a predetermined thickness, it is easy to form the wearing portion 10 lighter and thinner because the second core member 22 is thinner and lighter.

Particularly, the folding portion 16 and 26 may not be exposed through the second wearing portion 21 and the second core member 22. Thus, a slim headwear may be obtained in the bottom state shown in FIG. 2.

In addition, the first and second wearing portions 11 and 21, the first and second core members 13 and 22, and first and second size tapes 14 and 23 are sequentially disposed on each lower portion thereof. At this time, the first and second size tapes 14 and 23 are respectively sewed by sewing lines 110 and 115 at each lower portion of the first and second core members 13 and 22 along with each lower portion of the first and second wearing portions 11 and 21. Each lower portion of the first and second wearing portions 11 and 21 and the first and second core members 13 and 22 may be folded at one time to a predetermined height corresponding to each width of the first and second size tapes 14 and 23, and accordingly, they may be easily folded.

This is because the first and second size tapes 14 and 23 have a high elasticity in a vertical direction. In addition, the first and second size tapes 14 and 23 may maintain a predetermined size even though the first and second wearing portions 11 and 21 may be stretched. That is, the first and second size tapes 14 and 23 may not be stretched or easily torn.

In order to form the first wearing portion 11, a plurality of fabric pieces 11 a are connected with each other and then pre-sewed to form a seam portion 11 a′. The seam portion 11 a′ is divided with a predetermined distance of about 5 mm. Finally, the seam portion 11 a′ is finally sewed in one-to-one with a tape, in which the tape is cut at a predetermined width. The seam portion 11 a′ may not become thinker at a top of the headwear. That is, according to an exemplary embodiment of the present invention, since the seam portion 11 a′ is divided and sewed in one-to-one with the tape, the seam portion 11 a′ may not become thick at a top of the headwear, so that the headwear may have a slim design than the seam portion may be wrapped by the tape.

In order to form the second wearing portion 21, a plurality of fabric pieces 21 a are connected with each other and then are pre-sewed to form a seam portion 21 a′ as shown in FIG. 2.

It is one example that the second wearing portion 21 has the pre-sewed seam portion 21 a. Accordingly, the seam portion 21 a′ may be divided and sewed in one-to-one with the tape and wrapped with the tape.

It is because that the second wearing portion 21 may be in contact with the head and may comprise a relatively soft fabric having a high thermal sensation. That is, it is because that the seam portion 21 a′ of the second wearing portion 21 is thinner than the seam portion 11 a′ of the first wearing portion 11.

Now, how to manufacture a double-structure headwear is described with reference to FIG. 3 and FIG. 4.

Referring to FIG. 3, as described above, the first wearing portion 11 is formed by sewing a plurality of fabric pieces and then the seam portion 11 a thereof is finally sewed in one to one with a cut tape, and the second wearing portion 21 is formed by sewing a plurality of fabric pieces.

Then, the first and second core members 13 and 22, having a width greater than 7 cm (in the specification, the width is a height along a vertical direction) are disposed on each lower portion of the first and second wearing portions 11 and 21. The first and second size tapes 14 and 23 are then disposed on each lower portion of the first and second core members 13 and 22.

Since the first and second core members 13 and 22 respectively have a width greater than 7 cm, they may cover a forehead, absorb sweat from the forehead, and provide a cushioning property.

Next, the first and second wearing portions 11 and 21, the first and second core members 13 and 22, and the first and second size tapes 14 and 23 are entirely sewed by the sewing lines 110 and 115 at a tip of the first and second size tapes 14 and 23 such that they may be entirely combined with each other. It allows the manufacturing method of the double headwear to be easily automated because they may be entirely sewed with each other at one time.

The first and second size tapes 14 and 23 are attached to the first and second wearing portions 11 and 21, and then each lower portion of the first and second wearing portions 11 and 21 is folded by a predetermined height corresponding to each width of the first and second size tapes 14 and 23, and accordingly each lower portion of the first and second wearing portions 11 and 21 is opposed to each other.

At this time, the visor portion 30 is inserted at one end thereof between each lower portion of the first and second wearing portions 11 and 21 and then the visor portion 30 is firstly sewed at said one end thereof between each lower portion of the first and second wearing portions 11 and 21 by a sewing line 120.

The first and second size tapes 14 and 23 are respectively stitched by a stitch line 125 along with the first and second wearing portions 11 and 21 and the first and second core members 13 and 22 at about the middle of each width thereof.

In order to form a back surface of the headwear, as shown in FIG. 4, the first and second wearing portions 11 and 21 may be formed with a plurality of fabric pieces 11 a and 21 a, the first and second core members 13 and 22 having a thickness of about 7 cm are disposed on each lower portion of the first and second wearing portions 11 and 21, and then the first and second size tapes 14 and 23 are respectively disposed on each of the first and second core members 13 and 22. Each lower portion of the first and second core members 13 and 22 and each lower portion of the first and second wearing portions 11 and 21 are folded by a width of the first and second size tapes 14 and 23 to form each folded portion 16 and 26. Each lower portion of the folded portions 16 and 26 may be firstly sewed by the sewing lines 110 and 115. At this time, the first and second size tapes 14 and 23 are disposed on the first and second core members 13 and 22, so that each lower portion of the first and second wearing portions 11 and 21 as well as each lower portion of the first and second members 13 and 22 are easily folded by a predetermined height corresponding to each width of the first and second size tapes 14 and 23. Each folded portion 16 and 26 is opposed to each other, and the first and second core members 13 and 22 and the first and second size tapes 14 and 23 may be sewed at one time by a stitch line 125. The first and second wearing portions 11 and 21 may be connected by the stitch line 125 and may be finished at one time without additional winding members.

Now, thermal transmission characteristics of the headwear formed in this manner may be described using a thermal conductivity and contact thermal sensation measured by Thermo Labo II. The results thereof are as follows.

TABLE 1 A/Wool CP40's Poly Power consumption (W) 1.07 2.47 2.74 Fabric thickness (cm) 0.0812 0.0437 0.0410 Thermal conductivity 0.345 0.431 0.450 (10⁻³ W/cm) Contact thermal 0.079 0.165 0.152 sensation

As shown in Table 1, since the first wearing portion 11 is formed by a mixed spinning of acryl (A) and wool, it has a low thermal conductivity and a low contact thermal sensation. Accordingly, the first wearing portion 11 may have increased warmth retention. Meanwhile, since the second wearing portion 21 in contact with the head is formed by CP40's, that is, the mixed spinning of cotton and polyester of a ratio of 6 to 4, or by using 100% polyester, it has a high thermal sensation. Accordingly, it may provide a cool feeling when the user puts on the headwear. In addition, the first wearing portion 11 uses yarns of about 283 g/yd and the second wearing portion 21 uses yarns of about 240 g/yd or 180 g/yd, and accordingly, the wearer may feel the headwear light even though it is formed in a double structure.

Now, an external thermal shielding effect is indirectly tested using an apparatus such as Thermal Manikin. The external thermal shielding effect is measured by a power consumption for increasing a temperature of Thermal Manikin putting on a headwear A and B from 10° C. to 34° C. and maintaining the same at 34° C., wherein A is a conventional single-structure headwear (having a single fabric of the A/Wool of 283 g/yd) and B is a double-structure headwear(having an outer fabric of the A/Wool of 283 g/yd and an inner fabric of CP403 s of 240 g/yd). The double-structure headwear B having the first and second wearing portions 11 and 21 was manufactured as described above.

FIG. 5 illustrates a graph showing power consumption for maintaining a head temperature of the mannequin.

As shown in FIG. 5, it will be seen that the B head putting on the double-structure headwear B consumes a smaller heat flux than the A head putting on the single-structure A when maintained at a constant temperature of 34° C.

That is, it can be seen that the double-structure headwear has good warmth retention and has a relatively low thermal conductivity.

Meanwhile, the sewing method as described above may be performed by forming elastic yarns on the lower portion of the double-structure crown portion when the double-structure headwear is formed with an elastic material.

The above-described methods and apparatuses may not only be realized by the exemplary embodiment of the present invention, but, on the contrary, are intended to be realized by any double-structure headwear capable of using both surfaces, for example, an elastic headwear in which the back portion thereof is closed without having a size adjusting device, as well as a headwear having a size adjusting device, while realizing functions corresponding to the configuration of the exemplary embodiment of the present invention.

While this invention has been described in connection with what is presently considered to be a practical exemplary embodiment, it is to be understood that the invention is not limited to the disclosed embodiment, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

According to an exemplary embodiment of the present invention, the manufacturing process of the double-structure headwear is simply performed using an easily sewed core member, thereby enhancing productivity of the double-structure headwear.

According to an exemplary embodiment of the present invention, a double-structure headwear may provide excellent warmth retention.

According to an exemplary embodiment of the present invention, the double-structure headwear may have different inner and outer fabrics so that it may provide a slim design and a good cool feeling as well as the excellent warmth retention.

In addition, the headwear may have sweat-absorbing and cushioning functions without additional sweat absorbers, thereby reducing the number of constituent elements and the manufacturing process thereof.

In addition, the headwear may not cause an uncomfortable pressure, and may provide a slim design, such as a custom-made headwear.

In addition, since the minimum amount of a sewing line is exposed, the headwear may provide an excellent design. 

1. A double-structure headwear comprising: a first wearing portion; and a second wearing portion being disposed on an inner side of the first wearing portion, wherein the first and second wearing portions have each lower portion folded to a predetermined height in a vertical direction and sewed to each other, and the first wearing portion has a lower thermal conductivity and lower contact thermal sensation than that of the second wearing portion.
 2. The double-structure headwear of claim 1, further comprising first and second core members respectively disposed on each folded lower portion.
 3. The double-structure headwear of claim 1, further comprising a size tape having a constant length and entirely disposed on each lower portion of the first and second wearing portions.
 4. The double-structure headwear of claim 1, wherein the second wearing portion is formed by polyester.
 5. The double-structure headwear of claim 1, wherein the second wearing portion is formed by a mixed spinning of cotton and polyester in a ratio of 6 to
 4. 6. The double-structure headwear of claim 2, wherein the first and second core members are formed by a non-woven fabric.
 7. The double-structure headwear of claim 2, wherein the first core member is thicker than the second core member.
 8. The double-structure headwear of claim 7, wherein the first and second core members are formed by about 100% polyester, the first core member has a thickness of about 1.0 mm and a weight of about 101.56 g/m², and the second core member has a thickness of about 0.8 mm and a weight of about 78.12 g/m².
 9. The double-structure headwear of claim 3, wherein the size tape has high elasticity in a vertical direction.
 10. The double-structure headwear of claim 1, wherein the first and second core members have sweat-absorptive and cushioning properties.
 11. The double-structure headwear of claim 1, wherein the first wearing portion has a seam portion for connecting a plurality of fabric pieces and being pre-sewed with each other and sewed in one-to-one with a tape of a predetermined width, and the second wearing portion has a seam portion for connecting a plurality of fabric pieces and being pre-sewed with each other.
 12. A manufacturing method of a double-structure headwear, comprising: forming a first wearing portion including pre-sewing a plurality of fabric pieces to form a seam portion, dividing the seam portion in one-to-one, and again sewing the divided sewing portion in one-to-one with a tape; forming a second wearing portion including pre-sewing a plurality of fabric pieces having a higher thermal conductivity and higher contact thermal sensation than those of the first wearing portion; folding each lower portion of the first and second wearing portions to a predetermined height to form each folded portion; sewing in one-to-one each folded portion of the first and second wearing portions.
 13. The manufacturing method of claim 12, wherein the forming of the folded portions further comprises respectively disposing a first core member and a second core member thinner than the first core member on each lower portion of the first and second wearing portions, disposing a size tape on each lower portion of the first and second core members, and folding each lower portion of the first and second wearing portions along with each lower portion of the first and second core members by a width of the size tapes.
 14. The manufacturing method of claim 12, wherein the one-to-one sewing of the folded portions includes disposing one end of a visor portion between each folded portion of the first and second wearing portions, and entirely sewing the one end of the visor with the folded portions of the first and second wearing portions.
 15. The manufacturing method of claim 13, wherein the forming of the folded portions further comprises respectively stitching the first wearing portion, the first core member and the tip portion of the size tape along with the second wearing portion, the second core member, and the tip portion of the size tape.
 16. The manufacturing method of claim 13, wherein the first and second core members are formed of a non-woven fabric. 